Method and apparatus for assembling apertured elastic laminates

ABSTRACT

The present disclosure relates to methods for making apertured elastic laminates that may be used as components of absorbent articles. The methods and apparatuses may be close coupled such that materials may advance directly between aperturing and bonding operations. Such close coupling of devices may help to more precisely control the positions of the apertures in substrates relative to positions of apertures opposing substrates and/or bonds in the assembled laminate. The methods and apparatuses herein may also provide the ability to orient protrusions or protuberances in the substrates created by the aperturing process so as to extend inward and away from both outer surfaces of the assembled laminate. In turn, the assembly processes may be conducted so as to help mitigate reductions in softness that might otherwise result from the aperturing process in the assembled laminate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/903,501, filed on Jun. 17, 2020, which claims the benefit of U.S.Provisional Patent Application Ser. No. 62/874,600, filed on Jul. 16,2019, both of which are hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingapertured elastic laminates that may be used as components of absorbentarticles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from an advancing web or webs are combinedwith other individual components created from other advancing webs. Websof material and component parts used to manufacture diapers may include:backsheets, topsheets, leg cuffs, waist bands, absorbent corecomponents, front and/or back ears, fastening components, and varioustypes of elastic webs and components such as leg elastics, barrier legcuff elastics, stretch side panels, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles.

Some absorbent articles have components that include elastic laminates.Such elastic laminates may include an elastic material bonded betweentwo substrates. The elastic material may include an elastic film and/orelastic strands. In some laminates, elastic strands are joined betweentwo nonwovens while the elastic strands are in a stretched condition sothat when the elastic strands relax, the nonwovens gather between thelocations where the nonwovens are bonded to each other, and in turn,forms corrugations. The resulting elastic laminate is stretchable to theextent that the corrugations allow the elastic strands to elongate.

In some assembly processes, stretched elastic strands may be advanced ina machine direction and bonded between two advancing nonwovens to createan elastic laminate, wherein the stretched elastic strands are spacedapart from each other in a cross direction. Depending on where or how anelastic laminate may be used in an assembled product, it may bedesirable to enhance certain features of the elastic laminate. Forexample, if the elastic laminate is assembled for the purpose of beingconverted into an elastic belt on a diaper pant, it may be desirable toincrease the breathability of the elastic laminate to help enhance awearer's comfort during use of the diaper pant.

As such, the nonwovens may be subjected to a perforating or aperturingprocess during assembly to form apertures in the nonwovens. In turn, theapertures may help increase the breathability of the elastic laminate.However, advancement of the nonwovens between separate assemblyoperations and the stretchability of the nonwovens can increase thedifficulty in aligning the apertures in the individual nonwovens withrespect to each other and/or the bonding processes during laminateassembly. In turn, misalignment or misplacement of the apertures in thenonwovens may result in apertures being blocked or covered by theopposing nonwovens and/or by the bonds between the two substrates.Unintentional blocking of such apertures, may in turn, detract from thebreathability of the assembled laminate.

In an attempt to overcome the aforementioned problems associated withaperturing the individual nonwovens, some assembly processes may beconfigured to aperture the assembled laminate after assembly. However,subjecting an assembled elastic laminate to aperturing processes candetract from other desirable features of the elastic laminate, such assoftness. For example, in some aperturing processes, apertures arecreated in the elastic laminate by inserting pins or needles through thelaminate. When inserting pins through the laminate, the nonwovens may bedeformed and protrusions may be created where the apertures are formed.Such protrusions may extend outward from one surface of the laminate. Assuch, the surface of the resulting laminate that includes theprotrusions protruding therefrom may feel relatively rough.

Consequently, it would be beneficial to provide elastic laminates andmethods and apparatuses for producing such elastic laminates whereinapertures are positioned in desired locations with respect to each otherand/or with respect to bond regions while not detracting from thesoftness of the assembled laminate.

SUMMARY OF THE INVENTION

In one form, a method for making absorbent articles comprises steps of:forming first apertures in a first substrate, the first substratecomprising a first surface and an opposing second surface; advancingelastic material onto the second surface of the first substrate; formingsecond apertures in a second substrate, the second substrate comprisinga first surface and an opposing second surface; advancing the secondsubstrate onto the first substrate and elastic material to form alaminate, wherein the first surface of the second substrate is in afacing relationship with the second surface of the first substrate; andbonding the first substrate with the second substrate in bond regions,wherein the bond regions are separated from each other along the machinedirection to define unbonded regions, wherein the first apertures andthe second apertures are positioned in the unbonded regions.

In another form, a method for making absorbent articles comprises stepsof: providing a combining roll comprising an outer circumferentialsurface; providing a first aperturing device comprising a first roll andfirst pin members, the first roll adjacent the combining roll to definea first nip therebetween; providing a second aperturing devicecomprising a second roll and second pin members, the second rolladjacent the combining roll to define a second nip therebetween;advancing a first substrate to the first aperturing device, the firstsubstrate comprising a first surface and an opposing second surface;forming first apertures in the first substrate by penetrating the firstsubstrate with the first pin members; advancing first substrate throughthe first nip from the first roll of the first aperturing device ontothe combining roll with the first surface in a facing relationship withthe outer circumferential surface; stretching elastic strands in amachine direction; advancing the stretched elastic strands onto thesecond surface of the first substrate on the combining roll; advancing asecond substrate to the second aperturing device, the second substratecomprising a first surface and an opposing second surface; formingsecond apertures in the second substrate by penetrating the secondsubstrate with the second pin members; advancing the second substratethrough the second nip from the second roll onto the first substrate andthe stretched elastic strands on the combining roll to form a laminate,wherein the first surface of the second substrate is in a facingrelationship with the second surface of the first substrate; advancingthe laminate on the combining roll in the machine direction; and bondingthe first substrate with the second substrate of the laminate in bondregions, wherein the bond regions are separated from each other alongthe machine direction by unbonded regions, wherein the first aperturesand the second apertures are positioned in the unbonded regions.

In yet another form, an absorbent article comprises: an elastic laminatecomprising: a first substrate comprising a first surface and an opposingsecond surface, and first apertures surrounded by first protuberancesextending outward from second surface; a second substrate comprising afirst surface and an opposing second surface, and second aperturessurrounded by second protuberances extending outward from the firstsurface; elastic strands positioned between the first and secondsubstrates; the first substrate bonded with the second substrate in bondregions, wherein the second surface of the first substrate is in afacing relationship with the first surface of the second substrate, andwherein the bond regions are separated from each other by unbondedregions, and wherein the first apertures and the second apertures arepositioned in the unbonded regions; and an absorbent chassis connectedwith the elastic laminate.

In still another form, a method for making absorbent articles comprisessteps of: forming first apertures in a first substrate, the firstsubstrate comprising a first surface and an opposing second surface;advancing elastic material onto the second surface of the firstsubstrate; providing a second substrate, the second substrate comprisinga first surface and an opposing second surface; advancing the secondsubstrate onto the first substrate and elastic material to form alaminate, wherein the first surface of the second substrate is in afacing relationship with the second surface of the first substrate;bonding the first substrate with the second substrate in bond regions,wherein the bond regions are separated from each other along the machinedirection to define unbonded regions; and removing tension from thelaminate to form first corrugations in the first substrate and to formsecond corrugations in the second substrate, the first and secondcorrugations positioned between the bond regions, and wherein the firstapertures are positioned in the first corrugations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of a diaper pant.

FIG. 1B is a rear perspective view of a diaper pant.

FIG. 2 is a partially cut away plan view of the diaper pant shown inFIGS. 1A and 1B in a flat, uncontracted state.

FIG. 3A is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3B-3B.

FIG. 4A is a schematic side view of a converting apparatus adapted toassemble an apertured elastic laminate.

FIG. 4B is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an apertured elasticlaminate.

FIG. 4C is a schematic side view of another configuration of aconverting apparatus adapted to manufacture an apertured elasticlaminate.

FIG. 5 is a view of a first substrate taken along section 5-5 in FIGS.4A, 4B, and 4C.

FIG. 6 is a view of the first substrate with first apertures taken alongsection 6-6 in FIGS. 4A, 4B, and 4C.

FIG. 6A is a view of the first substrate with first apertures takenalong section 6A-6A in FIG. 6.

FIG. 6B is a detailed view of a pin member penetrating the firstsubstrate.

FIG. 7 is a view of a second substrate taken along section 7-7 in FIGS.4A, 4B, and 4C.

FIG. 8 is a view of the second substrate with second apertures takenalong section 8-8 in FIGS. 4A, 4B, and 4C.

FIG. 8A is a view of the second substrate with second apertures takenalong section 8A-8A in FIG. 8.

FIG. 8B is a detailed view of a pin member penetrating the secondsubstrate.

FIG. 9 is a view of elastics strands and the first substrate taken alongsection 9-9 in FIGS. 4A, 4B, and 4C.

FIG. 10 is a view of an elastic laminate taken along section 10-10 inFIGS. 4A, 4B, and 4C.

FIG. 10A is a view of the elastic laminate taken along section 10A-10Ain FIG. 10.

FIG. 11 is a view of the elastic laminate with bond regions taken alongsection 11-11 in FIGS. 4A, 4B, and 4C.

FIG. 11A is a view of the elastic laminate taken along section 11A-11Ain FIG. 11.

FIG. 12 is a view of the elastic laminate of FIG. 11 in a relaxed orcontracted state.

FIG. 12A is a view of an elastic laminate in a relaxed or contractedstate with corrugation lines that are not substantially perpendicular tothe machine direction.

FIG. 13A is a cross sectional view of the elastic laminate in a relaxedstate with apertures positioned in peaks of corrugations taken alongsection 13A-13A in FIG. 12.

FIG. 13B is a cross sectional view of an elastic laminate in a relaxedstate with apertures positioned in sides of corrugations.

FIG. 14 is a schematic view of a diaper pant assembly process.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Absorbentarticles can comprise sanitary napkins, tampons, panty liners,interlabial devices, wound dressings, wipes, disposable diapersincluding taped diapers and diaper pants, inserts for diapers with areusable outer cover, adult incontinent diapers, adult incontinent pads,and adult incontinent pants. The term “disposable” is used herein todescribe absorbent articles which generally are not intended to belaundered or otherwise restored or reused as an absorbent article (e.g.,they are intended to be discarded after a single use and may also beconfigured to be recycled, composted or otherwise disposed of in anenvironmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The terms “registration process,” “registration system,” “registration,”“register,” “registered,” or “registering” as used herein refer to amachine control process or system for controlling a substrate orlaminate, (which can have multiplicity of pre-produced objects, such asapertures, bonds, graphics, patterns, design elements, and/or insigniaspaced on the substrate or laminate at a pitch interval that may vary inthe machine direction) through a converting line producing articles, byproviding a positional adjustment of the pre-produced objects on thesubstrate or laminate to a target position constant associated with apitched unit operation of the converting line.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335,5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041,6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016,6,825,393, and 6,861,571; and U.S. Patent Publication Nos. 2013/0072887A1; 2013/0211356 A1; and 2013/0306226 A1, all of which are incorporatedby reference herein.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, to methods for making apertured elasticlaminates that may be used as components of absorbent articles. Withregard to the assembly processes described herein, first apertures areformed in a first substrate. Elastic material, such as elastic strands,is stretched in a machine direction and is advanced onto the firstsubstrate. Second apertures are formed in a second substrate, and thesecond substrate is advanced onto the first substrate and elasticmaterial to form a laminate. The first substrate is bonded with thesecond substrate in bond regions, wherein the bond regions are separatedfrom each other along the machine direction to define unbonded regions,wherein the first apertures and the second apertures are positioned inthe unbonded regions. Tension may be removed from the laminate to allowthe elastic material to contract and to form first corrugations in thefirst substrate and form second corrugations in the second substrate,wherein the first and second corrugations are positioned between thebond regions.

As discussed below, the methods and apparatuses may be close coupledsuch that materials may advance directly between aperturing and bondingoperations. Such close coupling of devices may help to more preciselycontrol the positions of the apertures in substrates relative topositions of apertures opposing substrates and/or bonds in the assembledlaminate. Enhanced control of the positions of the apertures may helpreduce and/or eliminate situations wherein apertures are unintentionallycovered or blocked by another substrate and/or by bonds between thesubstrates. In some configurations, first apertures in the firstsubstrate may be aligned with second apertures in the second substrateto define apertures that extend through the laminate. In someconfigurations, apertures may be positioned on peaks of the corrugationsin either or both the substrates of the laminate in a relaxed condition.In yet other configurations, one or more apertures may be positioned onwalls of the corrugations in either or both the substrates of thelaminate in a relaxed condition. As discussed in more detail below, oneor both the substrates may be apertured prior to laminate assembly, andthe aperturing process may also deform a substrate and createprotrusions or protuberances extending from one surface of thesubstrate. In turn, the methods and apparatuses herein provide theability to orient protrusions or protuberances in the substrates createdby the aperturing process so as to extend inward and away from bothouter surfaces of the assembled laminate. As such, the assembly processmay be conducted so as to mitigate reductions in softness that mightotherwise result from the aperturing process in the assembled laminate.

FIGS. 1A, 1B, and 2 show an example of an absorbent article 100 in theform of a diaper pant 100P that may include components constructed fromelastic laminates assembled in accordance with the apparatuses andmethods disclosed herein. In particular, FIGS. 1A and 1B showperspective views of a diaper pant 100P in a pre-fastened configuration,and FIG. 2 shows a plan view of the diaper pant 100P with the portion ofthe diaper that faces away from a wearer oriented toward the viewer. Thediaper pant 100P includes a chassis 102 and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt 106 and asecond elastic belt 108 are bonded together to form the ring-likeelastic belt 104.

With continued reference to FIG. 2, the diaper pant 100P and the chassis102 each include a first waist region 116, a second waist region 118,and a crotch region 119 disposed intermediate the first and second waistregions. The first waist region 116 may be configured as a front waistregion, and the second waist region 118 may be configured as back waistregion. The diaper 100P may also include a laterally extending frontwaist edge 121 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100P and chassis 102 of FIG. 2 are shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 121 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1A, 1B, and 2, the diaper pant 100P may include aninner, body facing surface 132, and an outer, garment facing surface134. The chassis 102 may include a backsheet 136 and a topsheet 138. Thechassis 102 may also include an absorbent assembly 140, including anabsorbent core 142, disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100Pmay also include other features, such as leg elastics and/or leg cuffsto enhance the fit around the legs of the wearer.

As shown in FIG. 2, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100P is worn on the lower torso of a wearer, the front waist edge 121and the back waist edge 122 may encircle a portion of the waist of thewearer. At the same time, the side edges 128 and 130 may encircle atleast a portion of the legs of the wearer. And the crotch region 119 maybe generally positioned between the legs of the wearer with theabsorbent core 142 extending from the front waist region 116 through thecrotch region 119 to the back waist region 118.

As previously mentioned, the diaper pant 100P may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may also comprise a woven or nonwovenmaterial, polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material. The backsheet may also comprise anelastomeric film. An example backsheet 136 may be a polyethylene filmhaving a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm(2.0 mils). Further, the backsheet 136 may permit vapors to escape fromthe absorbent core (i.e., the backsheet is breathable) while stillpreventing exudates from passing through the backsheet 136.

Also described above, the diaper pant 100P may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be liquid pervious, permittingliquids (e.g., menses, urine, and/or runny feces) to penetrate throughits thickness. A topsheet 138 may be manufactured from a wide range ofmaterials such as woven and nonwoven materials; apertured or hydroformedthermoplastic films; apertured nonwovens, porous foams; reticulatedfoams; reticulated thermoplastic films; and thermoplastic scrims. Wovenand nonwoven materials may comprise natural fibers such as wood orcotton fibers; synthetic fibers such as polyester, polypropylene, orpolyethylene fibers; or combinations thereof. If the topsheet 138includes fibers, the fibers may be spunbond, carded, wet-laid,meltblown, hydroentangled, or otherwise processed as is known in theart. Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Exemplaryapertured films may include those described in U.S. Pat. Nos. 5,628,097;5,916,661; 6,545,197; and 6,107,539, all of which are incorporated byreference herein.

As mentioned above, the diaper pant 100P may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735, all of which are incorporated byreference herein.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprise primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 A1 and 2004/0097895 A1, all of which areincorporated by reference herein.

As previously mentioned, the diaper 100P may also include elasticizedleg cuffs 156. It is to be appreciated that the leg cuffs 156 can be andare sometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730 A1, all of whichare incorporated by reference herein.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIGS. 1A and 1B.The ring-like elastic belt may be formed by joining a first elastic beltto a second elastic belt with a permanent side seam or with an openableand reclosable fastening system disposed at or adjacent the laterallyopposing sides of the belts.

As previously mentioned, the ring-like elastic belt 104 may be definedby a first elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2, the first elastic belt 106 extends between a firstlongitudinal side edge 111 a and a second longitudinal side edge 111 band defines first and second opposing end regions 106 a, 106 b and acentral region 106 c. And the second elastic 108 belt extends between afirst longitudinal side edge 113 a and a second longitudinal side edge113 b and defines first and second opposing end regions 108 a, 108 b anda central region 108 c. The distance between the first longitudinal sideedge 111 a and the second longitudinal side edge 111 b defines the pitchlength, PL, of the first elastic belt 106, and the distance between thefirst longitudinal side edge 113 a and the second longitudinal side edge113 b defines the pitch length, PL, of the second elastic belt 108. Thecentral region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIGS. 1A and 1B, the first endregion 106 a of the first elastic belt 106 is connected with the firstend region 108 a of the second elastic belt 108 at first side seam 178,and the second end region 106 b of the first elastic belt 106 isconnected with the second end region 108 b of the second elastic belt108 at second side seam 180 to define the ring-like elastic belt 104 aswell as the waist opening 110 and leg openings 112.

As shown in FIGS. 2, 3A, and 3B, the first elastic belt 106 also definesan outer laterally extending edge 107 a and an inner laterally extendingedge 107 b, and the second elastic belt 108 defines an outer laterallyextending edge 109 a and an inner laterally extending edge 109 b. Assuch, a perimeter edge 112 a of one leg opening may be defined byportions of the inner laterally extending edge 107 b of the firstelastic belt 106, the inner laterally extending edge 109 b of the secondelastic belt 108, and the first longitudinal or right side edge 128 ofthe chassis 102. And a perimeter edge 112 b of the other leg opening maybe defined by portions of the inner laterally extending edge 107 b, theinner laterally extending edge 109 b, and the second longitudinal orleft side edge 130 of the chassis 102. The outer laterally extendingedges 107 a, 109 a may also define the front waist edge 121 and thelaterally extending back waist edge 122 of the diaper pant 100P. Thefirst elastic belt and the second elastic belt may also each include anouter, garment facing layer 162 and an inner, wearer facing layer 164.It is to be appreciated that the first elastic belt 106 and the secondelastic belt 108 may comprise the same materials and/or may have thesame structure. In some embodiments, the first elastic belt 106 and thesecond elastic belt may comprise different materials and/or may havedifferent structures. It should also be appreciated that the firstelastic belt 106 and the second elastic belt 108 may be constructed fromvarious materials. For example, the first and second belts may bemanufactured from materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers) or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. In someembodiments, the first and second elastic belts include a nonwoven webof synthetic fibers, and may include a stretchable nonwoven. In otherembodiments, the first and second elastic belts include an innerhydrophobic, non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer substrate layer 162 andthe inner substrate layer 164. The belt elastic material may include oneor more elastic elements such as strands, ribbons, films, or panelsextending along the lengths of the elastic belts. As shown in FIGS. 2,3A, and 3B, the belt elastic material may include a plurality of elasticstrands 168 which may be referred to herein as outer, waist elastics 170and inner, waist elastics 172. Elastic strands 168, such as the outerwaist elastics 170, may continuously extend laterally between the firstand second opposing end regions 106 a, 106 b of the first elastic belt106 and between the first and second opposing end regions 108 a, 108 bof the second elastic belt 108. In some embodiments, some elasticstrands 168, such as the inner waist elastics 172, may be configuredwith discontinuities in areas, such as for example, where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, the elastic strands 168 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 168 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt. It is to be appreciated that thechassis 102 and elastic belts 106, 108 may be configured in differentways other than as depicted in FIG. 2. The belt elastic material may bejoined to the outer and/or inner layers continuously or intermittentlyalong the interface between the belt elastic material and the innerand/or outer belt layers.

In some configurations, the first elastic belt 106 and/or second elasticbelt 108 may define curved contours. For example, the inner lateraledges 107 b, 109 b of the first and/or second elastic belts 106, 108 mayinclude non-linear or curved portions in the first and second opposingend regions. Such curved contours may help define desired shapes to legopening 112, such as for example, relatively rounded leg openings. Inaddition to having curved contours, the elastic belts 106, 108 mayinclude elastic strands 168, 172 that extend along non-linear or curvedpaths that may correspond with the curved contours of the inner lateraledges 107 b, 109 b.

It is to be appreciated that the apparatuses and methods of assembly ofelastic laminates and absorbent articles described herein andillustrated in the accompanying drawings are non-limiting exampleconfigurations. The features illustrated or described in connection withone non-limiting configuration may be combined with the features ofother non-limiting configurations. Such modifications and variations areintended to be included within the scope of the present disclosure.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastic laminates that maybe used to construct various components of absorbent articles, such aselastic belts, leg cuffs, and the like. For example, FIGS. 4A-4C showschematic views of converting apparatuses 300 adapted to manufactureelastic laminates 200. As described in more detail below, the convertingapparatuses 300 operate to advance a continuous length of a firstsubstrate 202, a continuous length of a second substrate 204, and acontinuous length of elastic material 206 along a machine direction MD.It is also to be appreciated that in some configurations, the firstsubstrate 202 and second substrate 204 herein may be defined by twodiscrete single layer substrates or may be defined by multi-layeredlaminates. And in some configurations, the first substrate 202 and/orthe second substrate 204 may comprise nonwovens. The apparatus 300 formsapertures in either or both the first substrate 202 and the secondsubstrate 204. The apparatus may also stretch the elastic material 206and join the stretched elastic material 206 with the first and secondsubstrates 202, 204 to produce an elastomeric laminate 200. Although theelastic material 206 is illustrated and referred to herein as elasticstrands 208, it is to be appreciated that elastic material 206 mayinclude one or more continuous lengths of elastic strands, ribbons,and/or films.

As shown in FIG. 4A a converting apparatus 300 for producing an elasticlaminate 200 may include a first aperturing device 302 and a secondaperturing device 304 positioned adjacent a combining roll 306. Thecombining roll 306 may include an outer circumferential surface 308adapted to rotate about an axis 310. The first aperturing device 302 maybe positioned adjacent the combining roll 306 to define a firstcombining nip 312 therebetween, and the second aperturing device 304 maybe positioned adjacent the combining roll 306 to define a secondcombining nip 314 therebetween. In some configurations, a component,such as a roll discussed below, of the first aperturing device 302 maybe in direct contact with the combining roll 306 or may be separatedfrom the combining roll 306 such that a relatively short span of thefirst substrate 202 advances through the first combining nip 312 duringoperation. In some configurations, a component, such as a roll discussedbelow, of the second aperturing device 304 may be in direct contact withthe combining roll 306 or may be separated from the combining roll 306such that a relatively short span of the second substrate 204 advancesthrough the second combining nip 314 during operation. As shown in FIGS.4A and 5-8, the first aperturing device 302 is configured to form firstapertures 210 in the first substrate 202, and the second aperturingdevice 304 is configured to form second apertures 212 in the secondsubstrate 204. As shown in FIGS. 4A, 5, and 6, the first substrate 202comprises a first longitudinal edge 214 and a second longitudinal edge216 separated from the first longitudinal edge 214 in the crossdirection CD to define a width. The first substrate 202 also includes afirst surface 218 and an opposing second surface 220. Similarly, asshown in FIGS. 4A, 7, and 8, the second substrate 204 comprises a firstlongitudinal edge 222 and a second longitudinal edge 224 separated fromthe first longitudinal edge 222 in the cross direction CD to define awidth. The second substrate 204 also includes a first surface 226 and anopposing second surface 228.

With reference to FIGS. 4A and 5-11, during operation, the firstsubstrate 202 advances from the first aperturing device 302 through thefirst combining nip 312 and onto the combining roll 306. Elastic strands208 that are stretched in the machine direction MD may also advance inthe machine direction MD onto the first substrate 202 on the combiningroll 306. The second substrate 204 may advance from the secondaperturing device 304 through the second combining nip 314 and onto thefirst substrate 202 and stretched elastic strands 208 on the combiningroll 306 to form the laminate 200. In turn, the first substrate 202 andthe second substrate 204 are bonded together in bond regions 230,wherein the bond regions 230 are separated from each other along themachine direction MD to define unbonded regions 232. The first apertures210 and the second apertures 212 may be positioned in the unbondedregions 232. It is to be appreciated that the first substrate 202 andthe second substrate 204 may be bonded together in various ways, such asby heat, pressure, ultrasonic energy, and/or adhesive applied to atleast one of the first substrate 202 and the second substrate 204. Inaddition, the first substrate 202 and the second substrate 204 may bebonded together while positioned on the combining roll 306 or downstreamof the combining roll 306. As shown in FIG. 4A, the apparatuses 300herein may also include one or more guide rolls 316 that may be arrangedto guide the first substrate 202, the second substrate 204, and/orelastic material 206 to and/or from the aperturing devices 302, 304and/or the combining roll 306.

As shown in FIG. 4A, the first aperturing device 302 may include a firstperforator roll 318 adjacent a first anvil roll 320 to define a firstaperturing nip 322 therebetween. The first perforator 318 roll mayinclude an outer circumferential surface 324 and first pin members 326or needles protruding radially outward and adapted to rotate about anaxis 328. The first anvil roll 320 may include an outer circumferentialsurface 330 adapted to rotate about an axis 332 in a direction oppositethe first perforator roll 318. The first anvil roll 320 may be arrangedsuch that the first combining nip 312 is defined between the first anvilroll 320 and the combining roll 306, and wherein the first anvil roll320 and the combining roll 306 rotate in opposite directions. The firstsubstrate 202 may advance in the machine direction MD to the firstaperturing device 302 with the second surface 220 of the first substrate202 in a facing relationship with the outer circumferential surface 330of the first anvil roll 320. The first substrate 202 advances throughthe first aperturing nip 322 where the first pin members 326 penetratethe first substrate 202 and form first apertures 210 in the firstsubstrate 202.

As shown in FIGS. 4A, 6A, and 6B, the first pin members 326 may bedirected from the first surface 218 toward the second surface 220 of thefirst substrate 202. As the first pin members 326 penetrate the firstsubstrate 202, the first pin members 326 may deform the first substrate202 to define first protuberances 234 extending outward from secondsurface 220. In some configurations, the first protuberances 234 maycomprise substantially frustoconical shaped sides. With continuedreference to FIG. 4A, the first substrate 202 may advance on the outercircumferential surface 330 of the first anvil roll 320 from the firstaperturing nip 322 and through the first combining nip 312. As such, thefirst substrate 202 is transferred onto the combining roll 306 with thefirst surface 218 of the first substrate 202 in a facing relationshipwith the outer circumferential surface 308 of the combining roll 306. Assuch, the first protuberances 234 extend radially outward from thecombining roll 306.

With reference to FIGS. 4A and 9, elastic strands 208 are advanced inthe machine direction MD to the combining roll 306 and onto the secondsurface 220 of the first substrate 202. The elastic strands 208 areseparated from each other in the cross direction CD and are stretched inthe machine direction MD. In some configurations, the elastic strands208 may be advanced to the combining roll 306 in a stretched state. Insome configurations, the combining roll 306 may rotate such that theouter circumferential surface 308 advances at a higher speed than aspeed at which the elastic stands 208 are advanced to the combining roll306, which in turn, stretches the elastic strands 208 while advancingonto the combining roll 306. It is also to be appreciated that theelastic strands 208 may be supplied to the combining roll 306 in variousways and/or with various types of elastic unwinder configurations, suchas beams, overend unwinder or surface driven unwinder and unwinders,such as disclosed for example in U.S. Pat. Nos. 6,676,054; 7,878,447;7,905,446; and 9,156,648 and U.S. Patent Publication Nos. 2018/0168878A1; 2018/0168877 A1; 2018/0168880 A1; 2018/0170027 A1; 2018/0169964 A1;2018/0168879 A1; 2018/0170026 A1; and 2018/0070041 A1, which are allincorporated by reference herein.

Referring now to FIG. 4A, the second aperturing device 304 may include asecond perforator roll 334 adjacent a second anvil roll 336 to define asecond aperturing nip 338 therebetween. The second perforator roll 334may include an outer circumferential surface 340 and second pin members342 or needles protruding radially outward and adapted to rotate aboutan axis 344. The second anvil roll 336 may include an outercircumferential surface 346 adapted to rotate about an axis 348 in adirection opposite the second perforator roll 334. The second aperturingdevice 304 may also include a transfer roll 350 that may include anouter circumferential surface 352 adapted to rotate about an axis 354 ina direction opposite the second anvil roll 336. The transfer roll 350may be arranged such that a transfer nip 356 is defined between thetransfer roll 350 and the second anvil roll 336. The transfer roll 350may also be arranged such that the second combining nip 314 is definedbetween the transfer roll 350 and the combining roll 306, and whereinthe transfer roll 350 and the combining roll 306 rotate in oppositedirections. The second substrate 204 may advance in the machinedirection MD to the second aperturing device 304 with the first surface226 of the second substrate 204 in a facing relationship with the outercircumferential surface 346 of the second anvil roll 336. The secondsubstrate 204 advances through the second aperturing nip 338 where thesecond pin members 342 penetrate the second substrate 204 and formsecond apertures 212 in the second substrate 204.

As shown in FIGS. 4A, 8A, and 8B, the second pin members 342 may bedirected from the second surface 228 toward the first surface 226 of thesecond substrate 204. As the second pin members 342 penetrate the secondsubstrate 204, the second pin members 342 may deform the secondsubstrate 204 to define second protuberances 236 extending outward fromthe first surface 226. In some configurations, the second protuberances236 may comprise substantially frustoconical shaped sides. Withreference to FIG. 4A, the second substrate may advance on the outercircumferential surface 346 of the second anvil roll 336 from the secondaperturing nip 338 and through the transfer nip 356. As such, the secondsubstrate 204 is transferred onto the transfer roll 350 with the secondsurface 228 of the second substrate 204 in a facing relationship withthe outer circumferential surface 352 of the transfer roll 350. As such,the second protuberances 236 extend radially outward from the transferroll 350. In turn, the second substrate 204 may advance on the outercircumferential surface 352 of the transfer roll 350 from the transfernip 356 and through the second combining nip 314. As such, the secondsubstrate 204 is transferred onto the combining roll 306 with the firstsurface 226 of the second substrate 204 in a facing relationship withsecond surface 220 of the first substrate 202 and stretched elasticstrands 208 on the combining roll 306 to form the elastic laminate 200.As such, the second protuberances 236 extend radially inward toward theouter circumferential surface 308 of the combining roll 306.

As shown in FIGS. 4A, 10, 10A, 11, and 11A, the elastic laminate 200 mayadvance on the outer circumferential surface 308 of the combining roll306 to a bonding device 358 that bonds the first substrate 202 and thesecond substrate 204 together in bond regions 230. It is to beappreciated that the bonding device 358 may be configured in variousways. For example, as shown in FIG. 4A, the bonding device 358 may beconfigured to include the combining roll 306 and a pressing surface 360adjacent the combining roll 306 to define a nip 362 therebetween. Duringoperation, combining roll 306 rotates to advance the elastic laminate200 through the nip 362 between the combining roll 306 and the pressingsurface 360 to mechanically bond the first substrate 202 and the secondsubstrate 204 together. The combining roll 306 may also be configured toapply vacuum pressure to the elastic laminate 200 to help hold the firstand second substrates 202, 204 on the outer circumferential surface 308as the combining roll 306 rotates.

With continued reference to FIG. 4A, the bonding device 358 may beconfigured as a mechanical bonding device, wherein the combining roll306 may be configured as a pattern roll. As such, the outercircumferential surface 308 of the combining roll 306 may also compriseone or more bonding surfaces defined by bonding elements extendingradially outward. As the combining roll 306 rotates, the elasticlaminate 200 is advanced between the bonding surfaces and the pressingsurface 360 to mechanically bond or weld the first substrate 202 and thesecond substrate 204 together to create bond regions 230 between thebetween the first substrate 202 and the second substrate 204. Heatand/or pressure between the pressing surface 360 and the combining roll306 may melt and bond the first and second substrates 202, 204 togetherin areas supported by the bonding surfaces on the combining roll 306. Assuch, the mechanical bonds and/or bond regions 230 may have shapes thatcorrespond with and may mirror shapes of the bonding surfaces.

It is to be appreciated that the pressing surface 360 may be configuredin various ways. For example, as shown in FIG. 4A, the pressing surface360 may comprise an energy transfer surface 364 of an ultrasonic bondingdevice 366. As such, the bonding device 366 may include a horn 368 andmay be configured to impart ultrasonic energy to the elastic laminate200 on the combining roll 306. It is to be appreciated that aspects ofthe ultrasonic bonding device 366 may be configured in various ways,such as for example linear or rotary type configurations, and such asdisclosed for example in U.S. Pat. Nos. 3,113,225; 3,562,041; 3,733,238;5,110,403; 6,036,796; 6,508,641; and 6,645,330, all of which areincorporated by reference herein. In some configurations, the ultrasonicbonding device 366 may be configured as a linear oscillating typesonotrode, such as for example, available from Herrmann Ultrasonic, Inc.In some configurations, the sonotrode may include a plurality ofsonotrodes nested together in the cross direction CD.

It is to be appreciated that the bonding device 358 may be configured invarious ways, such as with heated or unheated pattern rolls, anvil rollsand/or ultrasonic bonding devices. In some configurations, the pressingsurface 360 may be configured as an outer circumferential surface of ananvil roll. Thus, as the elastic laminate 200 advances through the nip362, the first and second substrates 202, 204 may be mechanically bondedor welded together with pressure exerted between the pressing surface360 and the outer circumferential surface 308 of the combining roll 306.It is to be appreciated that the combining roll 306 and/or pressingsurface 360 may be configured to apply heat and pressure in various waysto perform mechanical bonding, such as for example, the mechanicalbonding devices and methods disclosed in in U.S. Pat. Nos. 4,854,984;6,248,195; 8,778,127; 9,005,392; 9,962,297; and 10,052,237, all of whichare incorporated by reference herein. It is also to be appreciated thatthe combining roll 306 may be configured as an anvil roll and thepressing surface 360 may be defined by the outer circumferential surfaceof a pattern roll.

In yet other configurations, the apparatus 300 may be configured withone or more adhesive applicator devices adapted to apply adhesive to thesecond surface 220 of the first substrate 202 and/or the first surface226 of the second substrate 204, wherein the first and second substrates202, 204 are bonded together with the applied adhesive in the bondregions 203. It is to be appreciated that such adhesive applicatordevices may be configured in various ways, such as for example, as aspray nozzle and/or a slot coating device. In some configurations, theadhesive applicator device may be configured in accordance with theapparatuses and/or methods disclosed in U.S. Pat. Nos. 8,186,296;9,265,672; 9,248,054; and 9,295,590 and U.S. Patent Publication No.2014/0148773 A1, which are all incorporated by reference herein. It isalso to be appreciated that adhesive may be applied to create the bondregions 230 in conjunction with or instead of the mechanical bondingprocesses discussed above.

With continued reference to FIGS. 4A, 11A, 12, and 13A, after the bondregions 230 are created, tension may be removed from the elasticlaminate 200, which in turn allows the elastic strands 208 to contractin the machine direction MD. In turn, first corrugations 238 are formedin the first substrate 202 and second corrugations 240 are formed in thesecond substrate 204. As shown in FIGS. 12 and 13A, the firstcorrugations 238 and second corrugations 240 are positioned in unbondedregions 232 between the bond regions 230. The first corrugations 238 andsecond corrugations 240 extend outward from the bond regions 230 inopposite directions, wherein the first corrugations 238 and secondcorrugations 240 each include walls 242 extending from the bond regions230 to a peak 244. The bond regions 230 may also define corrugationlines 241 in the elastic laminate 200 that extend in the cross directionCD between the first corrugations 238 and second corrugations 240.

As discussed above with particular reference to FIGS. 4A, 10A, and 11A,the arrangement of the various elements of the first aperturing device302 and the second aperturing device 304 and the combining roll 306 mayhelp to provide the ability to assemble elastic laminates 200 with thefirst protuberances 234 on the first substrate 202 and the secondprotuberances 236 on the second substrate 204 to be oriented so as toextend toward each other. In contrast to having the protuberances 234,236 extending outward from the elastic laminate 200, assembling theelastic laminate 200 with the protuberances 234, 236 extending inward orinternally of the elastic laminate 200 may help reduce roughness and/orrough feeling that may otherwise be caused by the aperturing processes.As such, it is to be appreciated that the apparatus 300 herein may beconfigured in various different ways to assemble elastic laminates 200with the internally extending/oriented protuberances 234, 236.

For example, as shown in FIG. 4B, the first aperturing device 302includes a first perforator roll 318 adjacent a first anvil roll 320 todefine a first aperturing nip 322 therebetween, such as described above.The first aperturing device 302 may also include a transfer roll 370that may include an outer circumferential surface 372 adapted to rotateabout an axis 374 in a direction opposite the first perforator roll 318.The transfer roll 370 may be arranged such that a transfer nip 376 isdefined between the transfer roll 370 and the first perforator roll 318.The transfer roll 370 may also be arranged such that the first combiningnip 312 is defined between the transfer roll 370 and the combining roll306, and wherein the transfer roll 370 and the combining roll 306 rotatein opposite directions. In operation, the first substrate 202 mayadvance in the machine direction MD to the first aperturing device 302with the first surface 218 of the first substrate 202 in a facingrelationship with the outer circumferential surface 324 and pin members326 of the first perforator roll 318. The first substrate 202 advancesthrough the first aperturing nip 322 where the first pin members 326penetrate the first substrate 202 and form first apertures 210 in thefirst substrate 202, such as shown with additional reference to FIGS. 5,6, and 6A.

As shown in FIG. 4B and as discussed above with reference to FIG. 6B,the first pin members 326 may be directed from the first surface 218toward the second surface 220 of the first substrate 202. As the firstpin members 326 penetrate the first substrate 202, the first pin members326 may deform the first substrate 202 to define first protuberances 234extending outward from the second surface 220. With continued referenceto FIGS. 4B, 5, and 6, the first substrate may advance on the outercircumferential surface 324 of the first perforator roll 318 from thefirst aperturing nip 322 and through the transfer nip 376. The firstsubstrate 202 is transferred onto the transfer roll 370 with the secondsurface 220 of the first substrate 202 in a facing relationship with theouter circumferential surface 372 of the transfer roll 370. As such, thefirst protuberances 234 extend radially inward toward the outercircumferential surface 372 of the transfer roll 370. In turn, the firstsubstrate 202 may advance on the outer circumferential surface 372 ofthe transfer roll 370 from the transfer nip 376 and through the firstcombining nip 312. As such, the first substrate 202 is transferred ontothe combining roll 306 with the first surface 218 of the first substrate202 in a facing relationship with the outer circumferential surface 308of the combining roll 306. As such, the first protuberances 234 extendradially outward from the combining roll 306. As shown in FIGS. 4B and9, elastic strands 208 are also advanced in the machine direction MD tothe combining roll 306 and onto the second surface 220 of the firstsubstrate 202 as described above.

With continued reference to FIG. 4B, the second aperturing device 304includes a second perforator roll 334 adjacent a second anvil roll 336to define a second aperturing nip 338 therebetween, such as describedabove. The second perforator roll 334 may be arranged such that thesecond combining nip 314 is defined between the second perforator roll334 and the combining roll 306, and wherein the second perforator roll334 and the combining roll 306 rotate in opposite directions. The secondsubstrate 204 may advance in the machine direction MD to the secondaperturing device 304 with the second surface 228 of the secondsubstrate 204 in a facing relationship with the outer circumferentialsurface 340 and second pin members 342 of the second perforator roll334. The second substrate 204 advances through the second aperturing nip338 where the second pin members 342 penetrate the second substrate 204and form second apertures 212 in the second substrate 204.

As shown in FIG. 4B and as discussed above with reference to FIG. 8B,the second pin members 342 may be directed from the second surface 228toward the first surface 226 of the second substrate 204. As the secondpin members 342 penetrate the second substrate 204, the second pinmembers 342 may deform the second substrate 204 to define secondprotuberances 236 extending outward from first surface 226. Withreference to FIGS. 4B and 10, the second substrate 204 may advance onthe outer circumferential surface 340 of the second perforator roll 334from the second aperturing nip 338 and through the second combining nip314. As such, the second substrate 204 is transferred onto the combiningroll 306 with the first surface 226 of the second substrate 204 in afacing relationship with second surface 220 of the first substrate 202and stretched elastic strands 208 on the combining roll 306 to form anelastic laminate 200. In addition, the second protuberances 236 extendradially inward toward the outer circumferential surface 308 of thecombining roll 306. Thus, as shown in FIGS. 4B, 10, 10A, 11, and 11A,the elastic laminate 200 may be assembled such that the firstprotuberances 234 on the first substrate 202 extend toward the secondsubstrate 204, and the second protuberances 236 on the second substrate204 extend toward the first substrate 202.

In another example, such as shown in FIG. 4C, the first aperturingdevice 302 may be configured in the same manner as the first aperturingdevice 302 described above with reference to FIG. 4A. Thus, the firstsubstrate 202 may advance on the outer circumferential surface 330 ofthe first anvil roll 320 from the first aperturing nip 322 and throughthe first combining nip 312. As such, the first substrate 202 istransferred onto the combining roll 306 with the first surface 218 ofthe first substrate 202 in a facing relationship with the outercircumferential surface 308 of the combining roll 306. In addition, thefirst protuberances 234 extend radially outward from the combining roll306. Elastic strands 208 are also advanced in the machine direction MDto the combining roll 306 and onto the second surface 220 of the firstsubstrate 202 as shown in FIG. 4C and as described above with referenceto FIG. 9. In addition, the second aperturing device 304 in FIG. 4C maybe configured in the same manner as the second aperturing device 304described above with reference to FIG. 4B. Thus, the second substrate204 may advance on the outer circumferential surface 340 of the secondperforator roll 334 from the second aperturing nip 338 and through thesecond combining nip 314. With reference to FIGS. 4C and 10, the secondsubstrate 204 is transferred onto the combining roll 306 with the firstsurface 226 of the second substrate 204 in a facing relationship withsecond surface 220 of the first substrate 202 and stretched elasticstrands 208 on the combining roll 306 to form an elastic laminate 200.In addition, the second protuberances 236 extend radially inward towardthe outer circumferential surface 308 of the combining roll 306. Again,as shown in FIGS. 4C, 10, 10A, 11, and 11A, the elastic laminate 200 maybe assembled such that the first protuberances 234 on the firstsubstrate 202 extend toward the second substrate 204, and the secondprotuberances 236 on the second substrate 204 extend toward the firstsubstrate 202.

It is also to be appreciated that the apparatuses shown in FIGS. 4A-4Cmay include additional anvil rolls and/or perforator rolls. In someconfigurations, the transfer rolls described above may also be adaptedto function as anvil rolls. In addition, the aperturing devices, anvilrolls, and/or perforator rolls herein may be constructed in various waysand/or operate in various ways, such as disclosed for example, in U.S.Pat. No. 4,886,632 and U.S. Patent Publication Nos. 2018/0228666 A1;2018/0228656 A1; and 2018/0228668 A1, all of which are incorporated byreference herein.

Although the various elements of the first aperturing device 302 and thesecond aperturing device 304 and the combining roll 306 may beconfigured to assemble elastic laminates 200 with the firstprotuberances 234 on the first substrate 202 and the secondprotuberances 236 on the second substrate 204 to be oriented so as toextend toward each other, it is also to be appreciated that theapparatuses herein may also be configured to assemble elastic laminates200 with one substrate having outwardly extending/oriented protuberancesand one substrate with internally/oriented protuberances. For example,the elastic laminate 200 may include a first substrate 202 with firstprotuberances 234 that extend outward and away from the second substrate204, and a second substrate 204 with second protuberances 236 thatextend inward and toward the first substrate 202. In addition, theapparatuses herein may also be configured to assemble elastic laminates200 with both substrates having outwardly extending/orientedprotuberances. For example, the elastic laminate 200 may include a firstsubstrate 202 with first protuberances 234 that extend outward and awayfrom the second substrate 204 and a second substrate 204 with secondprotuberances 236 that extend outward and away from the first substrate202.

As previously mentioned, the close coupled arrangement of the aperturingdevices 302, 304 and the combining roll 306 help provide the ability tomore precisely control the registration and/or positions and/orplacement of the apertures 210, 212 in the assembled laminate 200relative to each other. For example, as shown FIGS. 11 and 11A, thefirst substrate 202 and the second substrate 204 are bonded together inbond regions 230, wherein the bond regions 230 are separated from eachother along the machine direction MD to define unbonded regions 232. Thefirst apertures 210 and the second apertures 212 may be positioned inthe unbonded regions 232. In some configurations, such as shown in FIGS.10A, 11A, and 13A, the first apertures 210 and the second apertures 212may be aligned to define apertures 213 that extend completely throughthe elastic laminate 200. As such, it is to be appreciated that thefirst apertures 210 and the second apertures 212 may be aligned so as tohave substantially coterminous outer circumferences wherein theapertures 213 are shaped similar to the first and second apertures 210,212. In some configurations, the first and second apertures 210, 212 mayhave different shapes and/or may be aligned to partially overlap eachother to define apertures 213 having various different shapes and/orsizes. In some configurations, such as shown in FIG. 13A, the firstapertures 210 may be positioned on the peaks 244 of the firstcorrugations 238 and/or the second apertures 212 may be positioned onthe peaks 244 of the second corrugations 240. In some configurations,such as shown in FIG. 13B, the first apertures 210 may be positioned onthe walls 242 of the first corrugations 238 and/or the second apertures212 may be positioned on the walls 242 of the second corrugations 240.In some configurations, some first apertures 210 may be positioned onthe peaks 244 of the first corrugations 238 and some first apertures 210may be positioned on the walls 242 of the first corrugations 238 and/orsome second apertures 212 may be positioned on the peaks 244 of thesecond corrugations 240 and some second apertures 212 may be positionedon the walls 242 of the second corrugations 240. It is also to beappreciated that a plurality of first apertures 210 and/or secondapertures 212 may be positioned between the bond regions 230. Forexample, FIG. 13B shows two first apertures 210 and two second apertures212 positioned between the bond regions 230 and positioned in theunbonded regions 232.

The close coupled arrangement of the aperturing devices 302, 304 and thecombining roll 306 also help provide the ability to more preciselycontrol the registration and/or positions and/or placement of theapertures 210, 212 in the assembled laminate 200 relative to the bondregions 230 and corrugation lines 241 that may be defined thereby. Forexample, as shown in FIG. 12, the bond regions 230 and resultingcorrugation lines 241 may be oriented to extend in a direction that issubstantially perpendicular with respect to the machine direction MD. Assuch, the aperturing devices 302, 304 and the combining roll 306arrangements herein help control the registration and/or positionsand/or placement of the apertures 210, 212 along the machine directionMD in the assembled laminate 200 relative to the bond regions 230 andcorrugation lines 241. It is also to be appreciated that bondingequipment configurations may be adapted to create bond regions 230and/or resulting corrugation lines 241 that are not substantiallyperpendicular with respect to the machine direction MD such as shown inFIG. 12A and/or may extend in the cross direction CD in wavy or curvedlines. In turn, it is to be appreciated that the aperturing devices 302,304 and the combining roll 306 arrangements herein help control theregistration and/or positions and/or placement of the apertures 210, 212along the machine direction MD as well as the cross direction CD in theassembled laminate 200 relative to the bond regions 230 and corrugationlines 241.

As described above, it is to be appreciated that the elastic laminates200 herein can be used to construct various types of absorbent articlecomponents. For example, the elastic laminates 200 may be used as acontinuous length of elastomeric belt material that may be convertedinto the first and second elastic belts 106, 108 discussed above withreference to FIGS. 1-3B. As such, the elastic material 206 maycorrespond with the belt elastic material 168 interposed between theouter layer 162 and the inner layer 164, which in turn, may correspondwith either the first and/or second substrates 202, 204. For example, asshown in FIG. 14, when assembling diaper pants 100P, the elasticlaminate 200 may be converted into a first elastic belt laminate 200 aand/or a second elastic belt laminate 200 b (represented by the dashedarrow “A”). The first elastic belt laminate 200 a and the second elasticbelt laminate 200 b may be separated from each other in the crossdirection CD and may be connected with each other with a plurality ofchassis 102 intermittently spaced along the machine direction MD. Duringsubsequent assembly operations, the chassis 102 may be folded(represented by the dashed arrow “B”) so as to position the firstelastic belt laminate 200 a into a facing relationship with the secondelastic belt laminate 200 b. Bonds 246 may be applied to the overlappingbelt laminates 200 a, 200 b. Subsequently, discrete diaper pants 100Pmay be formed by separating the first and second belt laminates 200 a,200 b into first and second belts 106, 108 by cutting along the crossdirection CD through the first and second belt laminates 200 a, 200 badjacent the bonds 246 (represented by the dashed arrow “C”). As such,the bonds 246 may be divided to define the first and second side seams178, 180, respectively.

With further regard to incorporating the elastic laminates 200 hereininto various diaper assembly processes, it is also to be appreciatedthat the bond regions 230 discussed herein with reference to theaccompanying figures may be configured in various ways. For example, thebond regions 230, may be configured as anchoring bonds and trappingbonds or guiding bonds. More particularly, the anchoring bonds may beconfigured to anchor and bond discrete lengths of the stretched elasticstrands 208 with and between the first substrate 202 and the secondsubstrate 204, and trapping bonds may be configured to bond the firstand second substrates 202, 204 directly to each other, wherein thetrapping bonds may be separated from each other in a cross direction byat least one elastic strand 208, and as such, the elastic strands 208may be trapped between the trapping bonds. In some configurations, thetrapping bonds may be arranged to bond the first and second substrates202, 204 directly together without adhering the elastic strands 208 toeither substrate. As such, the trapping bonds may be configured to trapand immobilize discrete lengths of the elastic strands 208 between thetrapping bonds after the elastic strands 208 have contracted, such asdisclosed for example, in U.S. Pat. No. 6,291,039 and U.S. PatentPublication Nos. 2016/0331600 A1; 2018/0168880 A1; 2018/0170027 A1; and2018/0168879 A1, all of which are incorporated by reference herein.

It is also to be appreciated that the elastic laminates 200 herein maybe configured to be subjected to various elastic strand cuttingprocesses, sometimes referred to as tummy elastic cutting, to createdeactivated regions in the elastic laminate positioned along the machinedirection between elasticized regions by severing at least one stretchedelastic strand, wherein the at least one severed elastic strand retractsto at least one anchor bond. In some assembly operations, absorbentchassis 102 may be connected with the elastic laminate 200 in suchdeactivated regions. As such, it also to be appreciated that the methodsand apparatuses herein may be adapted to operate with various types ofabsorbent article assembly processes that may incorporate elasticlaminates assembled thereby, such as disclosed for example in U.S. Pat.Nos. 8,186,296; 9,265,672; 9,248,054; and 9,730,839 and U.S. PatentPublication Nos. 2013/0255861 A1; 2013/0255862 A1; 2013/0255863 A1;2013/0255864 A1; 2013/0255865 A1; 2018/0169964 A1; and 2018/0168879 A1,all of which are incorporated by reference herein. In other examples,the elastic laminates 200 herein may be used to construct various typesof leg cuff, backsheet, and/or topsheet configurations. In yet otherexamples, the elastic laminates may be used to construct waistbandsand/or side panels in taped diaper configurations.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: an elasticlaminate comprising: a first substrate comprising a first surface and anopposing second surface, and first apertures surrounded by firstprotuberances extending outward from second surface; a second substratecomprising a first surface and an opposing second surface, and secondapertures surrounded by second protuberances extending outward from thefirst surface; elastic strands positioned between the first and secondsubstrates; the first substrate bonded with the second substrate in bondregions, wherein the second surface of the first substrate is in afacing relationship with the first surface of the second substrate, andwherein the bond regions are separated from each other by unbondedregions, and wherein the first apertures and the second apertures arepositioned in the unbonded regions; and an absorbent chassis connectedwith the elastic laminate.
 2. The absorbent article of claim 1, theelastic laminate further comprising: first corrugations in the firstsubstrate; and second corrugations in the second substrate; wherein thefirst and second corrugations are positioned between the bond regions;and wherein the first and second corrugations each include wallsextending from the bond regions to a peak.
 3. The absorbent article ofclaim 2, wherein the first apertures are positioned on the peaks orwalls of the first corrugations.
 4. The absorbent article of claim 3,wherein the first apertures and the second apertures are aligned todefine apertures that extend through the elastic laminate.
 5. Theabsorbent article of claim 1, wherein the first protuberances comprisesubstantially frustoconical shaped sides.